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NIOEC-SP-45-14(0

)
DOCUMENT CODE NO. OF PAGES: 8
PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. DATE
NIOEC 000 EG ME SP 4514 A0 JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY
NATIONAL IRANIAN OIL ENGINEERING
& CONSTRUCTION COMPANY

NIOEC SPECIFICATION
FOR

PROCEDURE FOR REFRACTORY LINING

FIRST EDITION

JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY

JULY. 2005 NIOEC-SP-45-14(0) .

REV. REV. ZAKER M./A.A. JULY. DATE PREPARED CHECKED APPROVED AUTHORIZED . 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 PAGE PAGE PAGE PAGE 1 26 51 76 2 27 52 77 3 28 53 78 4 29 54 79 5 30 55 80 6 31 56 81 7 32 57 82 8 33 58 83 9 34 59 84 10 35 60 85 11 36 61 86 12 37 62 87 13 38 63 88 14 39 64 89 15 40 65 90 16 41 66 91 17 42 67 92 18 43 68 93 19 44 69 94 20 45 70 95 21 46 71 96 22 47 72 97 23 48 73 98 24 49 74 99 25 50 75 100 NOTES: 1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION. 3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL DOCUMENT. 5 4 3 2 1 0 JULY 2005 M. SAJEDI REV.F. THESE REMARKS SHALL BE INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.R.H.K.R. REV.A. 2005 NIOEC-SP-45-14(0) REVISION INDEX REV. 2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. M. 4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET. FARZAM M.

..........................................2 1.......... Equivalent to IPS Standard................. ADDENDUM TO IPS STANDARD (IPS-C-TP-352) ............................................................................................ INTRODUCTION.....................2 2..................... DEFINITIONS & TERMINOLOGY....... SCOPE...............................................................................................................3 3............................................................................ UNITS........................................................................... REFERENCES ........... 2005 NIOEC-SP-45-14(0) CONTENTS: PAGE NO..........2 2.................4 1 ...........................................3 4... JULY..................... 0.............................................................................................................3 5..................................................1..................................

the state of preparation necessary for the surface to be lined and thickness of lining shall be according to NIOEC-SP-45-07 2.It applies to equipment fabricated in metal or concrete and in both bonded and loose linings. vessels and the evaluation through compressive strength tests of insulating refractories which are field installed. relevant sections of Iranian Petroleum Standard IPS-C-TP-352 about refractory lining with the modifications as specified herein after shall be strictly followed. 1. IPS (IRANIAN PETROLEUM STANDARDS) IPS-E-TP-350 “Engineering Standard for Lining” IPS-C-TP-352 “Construction Standard for Lining” 2 . repair of lining and inspection of lined parts. Articles 1 through 4 of this document replace entirely the related articles in the referenced IPS Standard. C-865 “Practice for firing refractory concrete specimens”.This procedure pertains to materials. curing inspection and thermal drying of refractory linings for fired heaters. installation. application. to the extent specified herein. REFERENCES Throughout this Specification the following dated and undated standards/codes are referred to.Requirement for design and fabrication of the equipment. . the edition cited applies. boilers. application. 2005 NIOEC-SP-45-14(0) 0. ASTM (AMERICAN STANDARDS FOR TESTING AND MATERIALS) C-71 "Standard Terminology Relating to Refractories" C-93 "Test Methods for Cold Crushing Strength and Modulus of Rupture of Insulating Fire Brick" C-133 “Test Methods for cold crushing strength and modulus of rapture of insulating firebrick”. shall mutually be agreed upon by NIOEC and the Vendor/Contractor. C-860 “Practices for determining and measuring consistency of refractory concretes”. The applicability of changes in dated references that occur after the cited date. incinerators. the latest edition of the referenced document (including any supplements and amendments) applies. SCOPE . form a part of this Specification. C-268 "Preparing and Curing refractory Concrete Test Sample" C-309 “Liquid membrane forming compounds for curing concrete”. drying or curing. For dated references. These referenced documents shall. INTRODUCTION To satisfy the requirements of this NIOEC Specification. transportation. JULY. C-862 “Practice for preparing refractory concrete specimens by casting”. . . For undated references.This Specification includes requirements for preparation of material for use.

DEFINITIONS & TERMINOLOGY 4. or the Purchaser acting as the inspector. the inspector's or engineer's respective assistants properly authorized and limited to the particular duties assigned to them. procurement. JULY. Unless otherwise specified. (NIOEC) 4.5 “Inspector” means: The inspector or engineer employed by the Purchaser and acting as the Purchaser's representative. commissioning or management of a project or operation of a facility.4 “Contractor” means: The party which carries out all or part of the design. Equivalent to IPS Standard Substitute the following IPS Standards as referred to throughout IPS-C-TP-352 to relevant NIOEC's Specifications as follows: IPS Standard Relevant NIOEC Specification IPS-E-TP-350 NIOEC-SP-45-07 IPS-C-TP-352 NIOEC-SP-45-14 IPS-C-TP-101 NIOEC-SP-80-02 3. 4. 4. 4. 3 .1 “Employer” means: “National Iranian Oil Engineering & Construction Company”. 4. UNITS International System of units (SI) shall be used in accordance with NIOEC-SP-00-10.3 “Vendor” means: The manufacturer's from which the equipment is to be purchased. 2005 NIOEC-SP-45-14(0) IPS-C-TP-101 “Construction Standard for surface preparation” NIOEC-SP (NIOEC SPECIFICATIONS) NIOEC-SP-00-10 “NIOEC Specification for units” NIOEC-SP-45-07 “NIOEC Specification for Refractory Linings” NIOEC-SP-80-02 “NIOEC Specification for Painting” SIS (SWEDISH STANDARD) SIS 05 59 00 "Rust Levels of Steel Structure and Quality Levels for Preparation of Steel Surface for Rust Protecting Paints" 2. engineering. When quoted in this Specification as part of a direct purchase order by NIOEC and “Contractor” where this Specification is part of Contract Documents.1.2 “Purchaser” means: “National Iranian Oil Engineering & Construction Company”. construction.

17. If visual inspection warrents.9 Prior to application of refractory.1. . 2005 NIOEC-SP-45-14(0) 4. test anchor by sharply striking the ends of the anchor with a light hammer. Do not wash with water. Prepare the surface for the lining by thoroughly cleaning to remove all rust loose mill scale or other foreign materials. and other materials. The tube supports and other exposed structural items within the limits of the lining shall be wrapped with several layers of tarred or deadening felt to prevent the concrete from bonding to them.2 Preparation of Surface to be lined (Modification) Add the following sentences at the end of paragraph: .1.2.1 General (Modification) Add the following articles at the end of paragraph 17. 17. 4 . slag. Any anchor indicated to be unsatisfactorily welded shall be replaced and retested.7 Experience of Personnel Only personnel who are thoroughly familiar and experienced in application of refractory shall be employed in application of linings. 17. Properly fused welds give a ringing sound. 17.10 See NIOEC-SP-45-07 for details of types of anchors. defective welds give a dull. (see NIOEC-SP-80-02) . ASTM-C-71.9 Check pneumatic gun to assure that refractory wheels are included.2.1.2. JULY. flat sound. inspect all support anchors to make sure that anchors are attached securely to metal surfaces. Surface to be lined shall be thoroughly sand blasted (Sa 2) with sharp.1.8 Steel anchors shall be furnished by the Vendor and installed by the Contractor unless otherwise specified. rust. All sand blasting dust shall be removed before applying lining material.2. 5. Supervisors and foremen should have acted in a supervisory category on at least two previous jobs. ADDENDUM TO IPS STANDARD (IPS-C-TP-352) This addendum revises the below listed articles of the referenced standard as follows: 17. All temporary field attachments shall be removed.2 Mixing (Modification) Add the following article at the end of paragraph 17. abrasive sand or wire brushed to remove all unbounded scale. 17.1.1. Skilled tradesmen such as bricklayers and nozzle operators should have had at least one year's previous experience of such work on jobs of a similar nature.6 “Refractory” means: Non-metallic materials with chemical and physical properties applicable for structures and system components exposed to environments above 538°C (1000°F).

17. When application is interrupted or concrete is discontinued. .3. . u) To reduce rebound and dust and increase the quality of the castable lining due to reduction of stratification and increased uniformity. .4 Casting Process (Modification) Add the following paragraphs at the end of article: . Care should be taken at time of ordering to ensure that recommended shelf life is not likely to be exceeded before application. Immediately prior to resuming lining application. JULY. shall not be added to any mixture. They shall be lightly coated with tar or heavy grease to prevent bonding and shall not be removed until the concrete has developed its final set. the exposed surfaces of the refractory. This waste should be removed from mixer and discarded.1. All refractory shall be applied as per the Vendor’s detail application procedures approved by the Purchaser. Other cements. the surface shall be inspected for cleanliness. to which a bond will be made.3 Application Methods 17. Under no circumstances should this material be loaded into gun. the concrete shall be cut back to the steel platework with a steel trowel. shall be thoroughly wetted. Refractory should be predampened uniformly with just enough water added to the mixer to reduce dusting to a satisfactory level. Water at this point should be introduced by means of a fine spray to insure uniformity. v) Mixer blades should be cleaned frequently during a day’s operation by striking blades with a hammer to remove built up refractory. Mixing on a concrete floor is not permitted.3. . When the work is done during hot sunny weather the materials shall be stored in a shaded place until ready for use. Tools used in mixing and applying the refractory shall be kept clean and free of such substances.2 Refractory gunning method (Modification) Add the following paragraphs at the end of article: t) All refractory materials shall be thoroughly dry mixed in a paddle or ribbon type mixer before loading into gun chamber. .3. lime. . After these steps have been completed. and shall fit snugly into the openings. Since the tendency to wash out the binder and segregation of particles will occur. 2005 NIOEC-SP-45-14(0) .3. All material above the cut shall be discarded. There is also the danger of contamination by foreign particles. 17. This cut shall be made at locations where the full thickness has already been applied. Observation access and similar openings shall be fitted with sheet metal or wooden forms slightly tapered and of such dimensions that they extend beyond the finished surface of the concrete. etc. 5 .

4.10 After applying curing membrane. curing time in excess of 24 hours is required. However. Type .4.3.or when heat of hydration is first noted .3. 17.1 The finished surface shall be reasonably smooth.1(Modification) 6 .14 When first placed in service. Screeding shall follow directly after application and any deficiencies in thickness found during screeding shall be immediately corrected by applying additional material.3 Finishing of Castable Refractories (Addition) Add the following articles: 17. 17. The pigmented curing compound shall be applied to the refractory surface as soon as practicable after the disappearance of the sheen due to surface water.04 grams per sq. The curing compound shall be applied to the refractory surfaces with a fine mist spray until it is no longer absorbed. such as where soot blowers are used in fired heaters and in incinerator stacks.3.8 Freshly gunned hydraulic setting refractory linings may be cured with a fine water spray using an atomizing (fog) nozzle for 24 hours after material has taken its initial set (which generally occurs in about four hours) . an abrasion resistant wash shall be used to protect the surface of the refractory 17.8 Inspection and Test Methods 17.4. 17. free of impurities and from a chemical stand point good enough to drink. excessive troweling of the concrete shall be avoided.3. 2005 NIOEC-SP-45-14(0) w) Water for mixing the refractory shall be cool.3.4.8. to prevent any laminations occurring in the lining. Curing and Drying (Modification) Add the following articles at the end of paragraph 17. 17.12 Care shall be taken to prevent entrance of rain.13 After the water curing. The water temperature shall not be less than 5ºC. 17. the temperature of the equipment shall be raised slowly to gradually expel excess moisture. 17. If curing is done in an ambient temperature below 15ºC (60ºF). the lining shall be air dried for at least 24 hours by circulation of warm air.The liquid membrane forming compound used shall be pigmented and shall meet the requirements of ASTM-C-309. 17. 17. the lining shall be allowed to dry under ordinary atmospheric conditions for as long as possible but not less than 72 hours. JULY.3.3.3.cm. Except that the loss of water shall not exceed 0.9 Use of a liquid membrane forming curing compound is preferred . 17.4. This can be accomplished by screeding excess material from the surface.2.4.4.11 Curing with wet sacks spread on the surface of the lining shall not be permitted under any circumstances.4.2 In places where the refractory is subject to abrasions.

91 Refractory concrete tested in accordance with Specification NIOEC-SP-45-07 shall develop a minimum compressive strength of 110 bar (1600psi) for material whose density after drying at 104°C(220°F) for 18 hours is about 1360-1520Kg/m3 (85- 95lbs/ft3).8.3 Lining placed for which cored samples have failed shall be removed and replaced.5 After thermal dry-out per paragraph 10. further test specimens may be taken by coring to confirm condition of placed material.9.4 Prior to thermal drying.4 Sampling (Addition) 17.1 In addition to the pre-application tests outlined in article 17. C865.5 (Modification) The whole paragraph shall be modified as follows Samples shall be prepared and compression tested in 114 mm × 114 mm × 65mm test samples.9. Cracks of any size are not acceptable at this stage.8.8.2. 17. he shall check the thickness of applied refractory with the use of a depth gauge immediately after refractory has been applied.9. 2005 NIOEC-SP-45-14(0) Add the following paragraphs at the end of article . 17.9. but under no circumstances after material has taken it’s initial set. The minimum area removed shall be sufficient to expose at least three (3) anchors. representative samples shall be taken of the mix during application.8.2 A minimum of one test sample shall be taken cured for 24 hours and tested as follows: a) The first batch of refractory applied by each crew each day. JULY.5mm (1/16”) in width & 19mm 7 .9 Minimum Compressive Strengths (Addition) 17. 17.4. intervals.8. and laterally to sound refractory material. c) As further required by NIOEC’s appointed inspector.4. See attached sketch of depth gauge. Method of repair. 17. test all refractory linings by striking with a ball peen hammer 300-500gm (10 to 16-oz) at approximately 30 cm. . Small networks of cracks 1.2 of this Standard. in accordance with ASTM C133. 17. The sides of the cut shall be tapered back towards the vessel wall forming a keyed hole to form a stronger patch.2 Should failure to meet minimum compressive strength occur in materials already placed. Any voids or dry filled places will produce a dull sound. 17.0 a thorough visual examination shall be made of all refractory surfaces. Such areas shall be chiseled out completely to steel. 17. C862. Continuous observation shall be made by the Purchaser’s inspector. b) One for each stack lining. The Purchaser’s inspector shall make certain that the procedures outlined herein are followed. C860. curing and retesting shall be in accordance with the original procedure for installation. 17.

2005 NIOEC-SP-45-14(0) (3/4”) deep are considered normal. Areas showing larger cracks shall be considered for repair.10 Thermal Dry-Out(Addition) The Vendor shall submit thermal dry-out procedure for NIOEC's review and comment. Detailed application procedures shall be approved by the Purchaser. 8 . 17. JULY.